Originator: Stephen I. Dains/sdains
Page 20 of 29
Date Issued: 2-16-04
guidebookcommon spring 2004.doc
DateRevised: 5/27/2004
E1106
ADDEDCIRCUITS
•
Anelectrical loadanalysismust beperformed prior toadding circuits to theexistingOEM
wiring. The total circuit current draw, includingadditional circuits,must not exceed80
percent of theOEM circuit current protection rating for fuses located in thepassenger
compartment and60percent of theOEM circuit current protection rating for fuses in the
engine compartment. All added circuitsmust be properly fusedas describedbelowand in
the
BodyBuildersBook.
•
Whenadding circuitswithhigher current demands than thehost OEM circuit canprovide,
relays shouldbe incorporated into the system. TheOEMwiringmay beutilizedas a signal
source for the relay coil. Power to theadded circuit will thenbe supplieddirectly from the
vehiclebattery through the relay.
Added fusepanels shouldbe inanaccessible location for servicing.
•
Wiringadded to theOEM circuitmust beeither of the sameor greater gaugeas theOEM
wire towhich it is beingattached, depending on the lengthof theaddedwireand the current
drawof theadded load. SeeAppendix III for anElectrical Conductor SizingTable.
•
Thepower supplywire for added circuits from thebattery shouldbeproperly sized, include
appropriate fusing, and shouldbe connectedas follows:
> For circuits requiringamaximum total of 30amperes,make the connections at the starter
motor relay's positive terminal, not at thebattery's positive terminal. Thiswill aidbattery
serviceability.
•
> For circuits requiringmore than30amperes, make connections directly to thebattery's
positive terminal. Route thewirealong thebattery cable toprovideaneater wire routing
andassist battery serviceability.
•
When completinganE-Series auxiliary heater andair conditioning system, refer to
QVM
BulletinQ-19
,
E-SeriesAuxiliaryHeater andAir ConditioningConnectionPreparation
Package
, for theelectrical guidelines.
E1107
WIRING
Note: For thissection, the term "under hood" isdefinedas theenginecompartment area
rearwardof the front of theenginecooling radiator. The term "under body" is
consideredas theareabetween the frame rails. If thevehicledoesnot have frame rails,
(i.e., Freestar), theentireareaunder thevehicle is included in thedefinition.
All addedunder hoodandunderbodywiringmust be cross linkedpolyethylene, high
temperature (minimum125
°
C) insulatedwire. SAESpecification J1128SXL, GXL, or TXLwire,
or equivalent, is acceptable. For battery cablewiring, SAESpecification J1127TypeSGXor
STX is theminimumacceptable.
•
Normal PVC insulatedwire
maynot beused
under hoodor underbody.
•
Stranded conductor wiring shouldbeused for all low voltageapplications. Solidwiring is
unacceptable for low voltageuse.
•
All addedwiring shouldbe color codedor labeled toaid in servicing identification.
Theamount of wiringunder thehood shouldbeminimized. Locatewiringandaddedelectrical
devices in thepassenger compartment whenever possible.
•
Refer to "Conductor SizingTable" (Appendix III), todetermine theproper conductor length
and current draw for eachwiregaugeutilizedwhen splicing into theOEM circuitry.
•
"Pigtails" whichare suppliedas part of anadded component (light, power entry step, etc.),
whichdonotmeet the125°C insulation rating requirement,may be routed in theunder body
or under hoodarea if:
•
The length isminimized
It is not routedwithin12 inches of theexhaust or over theexhaust systemunless it is abovean
addedheat shield, incased inhigh temperature convolute, and is not touching theheat shield.
E1108
Addedwiringandwireharnesses shouldbeproperly routedand retained. Plastic or rubber
coatedmetal clamps shouldbeused to retain (carry theweight of) wireharnesses. Theuseof
plastic tie-wraps shouldbe limited tobundling the harness(es). Never tie-wrapor clampwire
harnesses tobrakeor fuel system lines or components.
